You are on page 1of 28

OEM Design-in guide

Philips Fortimo LED Linear Light Module system (LLM) - November 2009

• Philips Fortimo LED LLM1100 & 1800 in 3000 & 4000K

asimpleswitch.com
Contents
1. Introduction of Philips Fortimo LED Linear system 3 4. Designing a luminaire 17
1.1 Features and benefits 4 4.1 Introduction 17
1.2 Applications 4 4.2 IEC recommendations 17
4.3 Electrostatic device (ESD) measures 17
2. LEDs, the heart of the Fortimo Linear module 5 4.4 Wiring 17
2.1 What is a LED? 5 4.5 Optical design (Secondary optics) 17
2.2 LED packaging 6 4.6 Thermal management 18
2.3 Binning 6 4.6.1 Test requirements 18
2.4 LUXEON Rebel LEDs 6 4.6.2 Temperature range 18
2.5 Fortimo addresses the issue of binning 7 4.6.3 Critical temperature points (Tc) 18
2.6 Color consistency (SDCM) 7 4.6.4 Operation under built-in conditions 19
2.7 Miniaturization 7 4.6.5 Heat sink design 19
4.6.6 Heatsink material 19
3. Philips Fortimo LED LLM system 8
4.6.7 Thermal radiation and emission coefficient 19
3.1 The Fortimo LED LLM system components 8
4.6.8 Surface area 20
3.2 Nomenclature 8
4.6.9 Thermal design 20
3.3 Fortimo LED Linear portfolio 8
4.6.10 Calculation of thermal resistance 21
3.3.1 3000K 8
4.6.11 Thermal management 21
3.3.2 4000K 8
4.6.12 Calculating your heat sink 21
3.3.3 Future range extensions 9
4.7 Recommendations 22
3.4 Dimensions of Fortimo LED Linear system 9
4.7.1 Optical 22
3.5 Fixation (mechanical) 9
4.7.2 Thermal interface 22
3.6 Lighting performance characteristics 10
3.6.1 Photometric diagrams 10 5. Appendix 23
3.6.2 Spectral power distribution Fortimo LLM 11 5.1 Example Fortimo LED LLM solution 23
3.6.3 UV and other hazards 11 5.2 Complementary partners for optics 23
3.6.4 Photobiological safety aspects 11 5.3 Complementary partners for heatsinks 23
3.6.5 Measurements on the Fortimo LED LLM 12 5.4 Complementary partners for thermal interface material 23
3.7 Starting characteristics 12
3.8 Luminous flux during start period 12 Index of visuals 24
3.9 Constant Light Output (lumen maintenance) 12
3.9.1 The main benefits of a CLO system are the
optimized energy consumption and
improved system reliability 12
3.10 Lumistep dimming 13
3.11 Electromagnetic compatibility 13
3.12 Exposure to direct sunlight 14
3.13 Vibration and shocks 14
3.14 Standards and approvals 14
3.15 IP codes, dust and moisture protection 14
3.16 Glow-wire test 14
3.17 End-of-life behavior 14
3.18 About the Fortimo LED Linear Light module 15
3.19 About the Fortimo LLM driver 15
3.20 About the Fortimo LLM cable 16
3.21 Fortimo LED LLM System disposal 16

 Design-in guide Philips Fortimo LED Linear system


1. Introduction of Philips Fortimo LED Linear system
Thank you for choosing the Philips Fortimo LED LLM system.
This guide tells you all about this system. If you require any further
information or support please consult your local Philips office or visit:
www.philips.com/support or
www.philips.com/fortimo.

The advantages of LEDs have been known for 40 years:


Fortimo LLM module
• Long life – low maintenance cost.
• Robustness – high reliability.
• Saturated colors – maximum visual effect.
• Cool beam – no heating of illuminated products.
• No UV or IR – wide application possibilities.
• Low-voltage operation – more safety, ease of use.
• Mercury-free – care for the environment.

Rapid improvements in high-power LED technology mean that LEDs can now
Fortimo LLM driver
be used for the first time in ‘real’ lighting applications, providing improvements
over traditional lighting systems. The use of LEDs has implications for lighting
manufacturers in terms of differences in solid-state lighting usage compared with
traditional lamps: for example how to design given the constant improvements in
specifications; how to provide the necessary heat sinking and how to deal with
variations in flux and/or color. The Philips Fortimo LED LLM system addresses
these differences and facilitates easy adoption of LED technology for high lumen
packages. The system is designed for integration in luminaires (system).This
technical application guide addresses the relevant issues to support and facilitate
the work of specifiers and lighting system designers.

Fortimo LED Linear system is primarily designed for luminaires in outdoor


use, but can also be used in certain indoor applications as long as this creates
no design conflicts with the Fortimo LED Linear system and the European
luminaire standards are respected (EN60598). Please consult us if you wish to
deviate from the design rules as described in this application guide. Meanwhile
also complementary businesses especially for heat sink and reflector design are
developing around Fortimo LED LLM systems. In the application guide you will also
find references to heatsinking and reflector manufactures.

Design-in guide Philips Fortimo LED Linear system 


1.1 Features and benefits
Features Benefits
Constant Light Output (CLO) No light depreciation
Linear shaped LED module Easily creation of uniform and retangular lightpatterns
Directed light output (batwing distribution) Reducing light polution (no sky glow)
Fortimo technology applied (RP film layer) High efficient, energy saving lighting (>64lm/W at system level)
Fixed form factor (Lumen packages 1000-4500) Reduced Time To Market (TTM) and related cost for OEMs
Latest LED technology inside ensuring performance and availability Reduced LED supply chain complexity for OEMS
No mercury Environmental friendly
Long lifetime (50Khrs) Reliable (system approach)
CCT 3000K & 4000K / Ra 75 and good color consistency Comfortable and safe high quality LED light
Easy replacement (not sealed for life) Upgradeable

1.2 Applications
Examples are:
• Residential.
• City centre.
• Square.
• Park.
• Wall washing.
• Flood lighting.
Residential area application • General lighting.

City Application

Outdoor Park application

 Design-in guide Philips Fortimo LED Linear system


2. LEDs, the heart of the Fortimo Linear module
The development of Light Emitting Diodes (LEDs) is progressing
at such a pace that they are rapidly gaining importance for lighting
applications. To most people, the term LED still only means the small
indicator lights that show whether the TV set is switched on.These
tiny light sources barely emit enough light to make them selves visible.
However, breakthroughs made in the last few years now allow LEDs
to be used for ‘real’ lighting applications that have traditionally been
the domain of incandescent lamps and discharge lamps. The Philips/
Agilent joint venture Lumileds was the first to bring high power LEDs
for lighting applications to the market under the Luxeon trademark.
Luxeon emitters are among the highest-performance LEDs in the
world, allowing us to offer the brightest solid-state lighting solutions.

2.1 What is a LED?


LEDs are solid-state devices, built up from crystalline layers of semiconductor
material.The light generation process makes use of the special electronic
properties of crystalline semiconductors in a process called injection luminescence.
In brief, this means the injection of charged particles by an electric field from one
semiconductor layer into another, where they are able to relax to a lower-energy
state by emitting visible light. LEDs produce narrow light spectra.The bandwidth
remains limited to a few tens of nanometers, and are therefore perceived by
the human eye as a single, deeply saturated color. LEDs are now available in all
wavelength regions of the visible spectrum; yellow is the only region in which no
high-power LED is currently available.White light can be produced by combining
LEDs of different colors (for instance red, green and blue), or by applying phosphor
coatings on blue or ultraviolet LEDs. Like many other lamps, LEDs cannot be
connected directly to the mains.The LEDs have to be operated at a stabilized
low voltage, which is provided by Driver electronics. However, LEDs do not need
ignition and can be switched within milliseconds. LEDs do not generate nearly as
much heat as many otherlamps, but that does not mean that thermal design is not
important. LEDs do produce heat when they operate, and are themselves relatively
sensitive to temperature.Thermal considerations are therefore very important
aspects of LED lighting system design.

Design-in guide Philips Fortimo LED Linear system 


2.2 LED packaging
The bare LED die is still a very sensitive and fragile device that must be handled in
a clean room environment. Before bringing them outside, they must be packaged.
The light flux of conventional LEDs, for example those used as indicator lights
on TV sets, is severely limited by the amount of heat generated. In practice,
conventional LED packages are limited to about 0.15 W at most, and emit only
a few lumens.Their light is too weak to be used for illumination purposes, and
they can only be used for luminance applications (i.e. when the light source is
intended to be viewed directly). A breakthrough came with a new package design
invented by Philips Lumileds, which guides away the heat generated at the diode
LUXEON Rebel LED junction much more efficiently. LEDs based on this package are sold under the
trademark Luxeon. Instead of an epoxy cap, the chip is encapsulated in a silicone
gel covered by a polymer lens. Using two different materials for encapsulation and
Silicone Lens for the primary optics allows better optimization of material properties for heat
management and lifetime.The slug is a large metal body that takes up the heat from
TVS
the chip and provides a low-thermal-resistance route to the outside world.This
package design now makes high-power LEDs feasible.

Cathode
LED Chip 2.3 Binning
Bond Layer The subject of binning should be explained because of its importance in LED
system design.As in other semiconductor manufacturing processes, in LED
Ceramic Substrate
Metal Interconnect Layer production the number of parameters of the epitaxy process is very large and the
Thermal Pad
(electrically isolated) process window small (for example, the temperature must be controlled to within
Cutoff section LED 0.5 °C (<1 °F) across the wafer at temperatures of ~800 °C/1470 °F).The difficulty
of achieving such a high degree of control means that the properties of the LEDs
may vary significantly within single production runs and even on the same wafer.To
obtain consistency for a given application, binning (= selection in bins) is mandatory.
Binning involves characterization of the LEDs by measurement and subsequently
categorizing them into several specific bins.To keep the cost per LED down, LED
manufacturers must sell the full production distribution.At the same time they
cannot guarantee the availability of all bins at all times.There is a trade-off between
logistics and cost price on the one hand, and the application requirements on the
other. Setting the specification too tightly will increase the cost price and may
lead to logistics problems. System design should therefore try to combine LEDs
from different bins intelligently to obtain the required system performance at a
reasonable price and with reasonable delivery reliability.

2.4 LUXEON Rebel LEDs


LUXEON Rebel is the smallest surface mountable power LED available today.With
the industry’s best lumens per package, highest light density (lumens per mm2), and
the highest packing density, LUXEON Rebel is ideal for both space constrained and
conventional solid lighting applications. Due to the small mounting surface we have
been able to use multiple LUXEON Rebel within the Fortimo products in order to
match required high lumen packages.

 Design-in guide Philips Fortimo LED Linear system


2.5 Fortimo addresses the issue of binning
High-quality LED light is achieved by mixing the light of blue LEDs and applying a
special Fortimo phosphor technology remote from the LEDs. High-quality white
light for outdoor applications is characterized by a color rendering of minimal 70,
popular CCTs in general lighting applications of 3000 K and 4000 K and a color
consistency comparable with conventional PLL and HID solutions (five to seven
SDCM).

0,450
2.6 Color consistency (SDCM)
The target specification of Fortimo LED LLM systems for color consistency is
5 SDCM @ 0-hours and 7 SDCM @ 10K hrs.This is a similar specification as for
conventional PLL lamps. SDCM stands for Standard Deviation of Color Matching
and the value 5 refers to the size of an ellipse around the black body locus.
Staying within this ellipse results in a consistency of light that ensures that from
CIE y

one luminaire to another no difference can be noticed.

In the visual we have plotted > 150 Fortimo LED LLM systems and you can see
they all fit within the 5 SDCM ellipse.This really demonstrates the unique quality of
0,350
0,370 0,380 0,390 0,400 0,410 0,420 0,430 0,440 0,450 0,460 0,470 the remote phosphor concept.We also plotted these results in a typical bin
CIE x
BBL distribution sheet of Philips Lumileds. As you can see all Fortimo’s fit within 1 bin!
3000K
4000K
Typically you can buy 6 to 12 bins combinations, not so precise as the 1-bin result
7 SDCM off BBL 3000K of Fortimo.
7 SDCM off BBL 4000K
5 SDCM off BBL 3000K
5 SDCM off BBL 4000K
measurements high flux
2.7 Miniaturization
LL_NW_bins LEDs are typically much smaller than conventional light sources. Lighting designers
LL_WW_bind
and specifiers immediately recognized the fact that LEDs allow dramatically
Color consistency (SDCM)
different lighting designs that capitalize on these tiny, unobtrusive light sources.This
is understandable, but care must also be taken to deal with the heat produced by
power LEDs. Proper heat management places limits on miniaturization.

Design-in guide Philips Fortimo LED Linear system 


3. Philips Fortimo LED LLM system
The Fortimo LED LLM portfolio is a complete range. It is primarily designed for
luminaires in outdoor use, but can also be used in certain indoor applications.
Further extensions of the portfolio will be in high lumen packages and
programmable dimming features. The future range extensions will make use of the
current form factor to build further on the future proof promise of Fortimo LED
systems. As the system is future proof it will be possible to replace and upgrade
the system without modifying the luminaire.

Fortimo LED Linear System 3.1 The Fortimo LED LLM system components
• Fortimo LED Linear Light Module.
• Fortimo LLM Driver.
• Fortimo LLM Cable 25 cm.

3.2 Nomenclature
Philips Fortimo LED LLM1800 Philips Fortimo LED LLM1800
28W/730 220-240 28W/730 LS-8

Philips Brandname Philips Brandname


Fortimo Family type Fortimo Family type
LED LED system LED LED system
LLM Fortimo type discriptor LLM Fortimo type discriptor
1800 Light output 1800 Light output
28W Energy consumption System 28W Energy consumption System
730 CRI+CCT 730 CRI+CCT
220-240 Voltage range LS-8 Lumistep 8 hrs dimming
Note LS stands for the lumistep dimming protocal. See dedicated chapter (3.8) for
details about lumistep.

3.3 Fortimo LED Linear portfolio


3.3.1 3000K
Fortimo LED LLM1800 28W/730 220-240V
Fortimo LED LLM1800 28W/730 LS-6
Fortimo LED LLM1800 28W/730 LS-8
Fortimo LED LLM1800 28W/730 LS-10

Fortimo LED LLM1100 17W/730 220-240V


Fortimo LED LLM1100 17W/730 LS-6
Fortimo LED LLM1100 17W/730 LS-8
Fortimo LED LLM1100 17W/730 LS-10

3.3.2 4000K
Fortimo LED LLM1800 25W/740 220-240V
Fortimo LED LLM1800 25W/740 LS-6
Fortimo LED LLM1800 25W/740 LS-8
Fortimo LED LLM1800 25W/740 LS-10

Fortimo LED LLM1100 15.5W/740 220-240V


Fortimo LED LLM1100 15.5W/740 LS-6
Fortimo LED LLM1100 15.5W/740 LS-8
Fortimo LED LLM1100 15.5W/740 LS-10
 Design-in guide Philips Fortimo LED Linear system
3.3.3 Future range extensions
Fortimo LED Linear with higher lumen packages (3000, 4500 and 8000).
Fortimo LED Linear with programmable dimming possibilities.
Fortimo LED Linear with CRI of 80+.

3.4 Dimensions of Fortimo LED Linear system

Fortimo LLM module

Fortimo LLM driver

A1 B1 C1 D1 E1 F1 F3 G1 G2 G3 H1
230.0 45.0 42.0 214.5 4.5 123.0 110 79.0 67.0 4.5 33.0
Dimensions in mm.

3.5 Fixation (mechanical)


The separate components (Driver and Module) of the Fortimo LED LLM system
can be securely fastened by the mounting holes located on the module and driver.
Please refer to dimensional drawing for the specific details such a pitch and
diameter.

The 3D CAD files will be available for downloading from www.philips.com/fortimo.


For fixation of the system we advise to use hexagon socket head cap screw M4
(DIN 912 / ISO 4762) with a spring lock washer for screws with cylindrical heads
M4 (DIN 7980) of Stainless steel A2 (DIN 1.4301 / AISI 304).

Design-in guide Philips Fortimo LED Linear system 


3.6 Lighting performance characteristics
3.6.1 Photometric diagrams

Polar diagrams Fortimo LED Linear

Batwing light distribution

10 Design-in guide Philips Fortimo LED Linear system


3.6.2 Spectral power distribution Fortimo LLM

Special Power Distribution Fortimo LLM 3000 K Special Power Distribution Fortimo LLM 4000 K
0,04 0,035

0,035 0,03

0,025 0,025

0,02 0,02

0,015 0,015

0,01 0,01

0,005 0,005

0 0
300 400 500 600 700 800 300 400 500 600 700 800

Wavelength (nm) Wavelength (nm)

3.6.3 UV and other hazards


PET value >100 hrs./Klux (zero UV)
Damage factor 0.08 @ 4100 K
IR (infrared) radiation As well as being free of UV radiation, the LED modules are
also free of infrared radiation in the beam.

3.6.4 Photobiological safety aspects


As of March 2007, LEDs and LED-based products for general lighting are no longer
included in the scope of the Eye Safety standard for lasers, IEC 60825-1 ‘Safety
of laser products’. The new lamp standard, IEC 62471 ‘Photobiological safety of
lamps and lamp systems’, covering incoherent light sources, is now applicable. This
international standard gives guidance for evaluating the photobiological safety of
lamps and lamp systems including luminaires. Specifically it specifies the
exposure limits, reference measurement technique and classification scheme
for the evaluation and control of photobiological hazards from all electrically
powered incoherent broadband sources of optical radiation, including LEDs but
excluding lasers, in the wavelength range from 200 nm through 3000 nm. In the
photobiological safety standard, hazard categories are defined as follows:

Radiance-based:
• Blue Light LB 300 – 700 nm
• Retinal Thermal LR 380 – 1400 nm
• Retinal Thermal Weak Stimulus LIR 780 – 1400 nm
Irradiance-based:
• Actinic UV Skin & Eye ES 200 – 400 nm
• Eye UVA EUVA 315 – 400 nm
• Blue Light Small Sources EB 300 – 700 nm
• Eye IR EIR 780 – 3000 nm

Design-in guide Philips Fortimo LED Linear system 11


Hazard Category Emission Limit 3.6.5 Measurements on the Fortimo LED LLM
LB Low (Risk Group 1) The following should be taken into account: The effective radiance measurement
LR Exempt* for Blue Light (LB) modules is ‘Low’, meaning that the LED modules are
LIR Exempt categorized in Risk Group 1. F=or the 1800 lumen version, the permitted exposure
ES Exempt time for Blue Light radiance (relevant when looking into the source) is limited to
EUVA Exempt 1.5 hours, while for the 1100 lumen version it is 3 hours. Because of the Law of
EB Exempt Conservation of Radiance, integrating the LED module into a luminaire results in
EIR Exempt either the same radiance or a reduced radiance. Final assessment of the luminaire
Emission limit is recommended.
* Exempt means ‘no risk’. • The measured irradiance-based values (E) for the categorized hazards are all
within the exempt group (both 1100 and 1800 lumen versions).
• In general the permitted exposure time for irradiance is limited when in the
‘low’,‘moderate’ or ‘high’ risk group. Limiting the exposure time and/or the
distance to the source can reduce the hazard level. However, for the measured
LED modules there are no special precautions necessary since they are ranked
in the exempt group. Final assessment of the luminaire (including e.g. secondary
optics) is recommended.

Photobiological safety is not assured if the Fortimo LED module is

! lit up without the cover. Direct exposure to the blue LED light is
dangerous for the eyes.

3.7 Starting characteristics


The system can be switched on in milliseconds, which is a general characteristic of
LEDs. It is planned to have a programmable outdoor driver, making it possible to
switch in milliseconds to any dimming level for any length of time.

3.8 Luminous flux during start period


In contrast to other light sources, LEDs can be switched on at full power (or at
any other dimmed level) instantaneously. The Fortimo LED LLM system requires an
initial burning-in time of 100 hours to reach the listed specifications because of the
combination of the LEDs and the remote phosphor used in the modules.

3.9 Constant Light Output (lumen maintenance)


The Fortimo Led Linear system has been equipped with a special feature CLO
(Constant Light Output), when used within specification a lumen maintenance of
100%
100% is expected at 50,000 hours (average lifetime specification).
Overlighting

3.9.1 The main benefits of a CLO system are the optimized energy consumption
Require lightlevel

and improved system reliability


Fortimo LED linear with CLO
Conventional lighting solution The main difference between a CLO system and a conventional system or standard
Standard LED solution
LED light system is that with CLO the end-user always has the required light level;
there is no overlighting (see picture Overlighting CLO). The CLO feature uses a
Burning hours x1000 25 50
predictive algorithm to increase the current to the LED over the specified lifetime
Overlighting versus CLO
of 50Khrs. As the current increases also the energy consumption increases with
about 20%. Compared to a conventional PLL 36W (40W system level) an energy
saving of 23% for warm white and 31% for neutral white can be achieved. These
savings can even be increased to respectively 42% and 48% when the lumistep
(8 hrs) version is used.

12 Design-in guide Philips Fortimo LED Linear system


Lumistep 8 hrs dimming
3.10 Lumistep dimming
for the Netherlands in January
To enable even further energy savings a special feature has been integrated in the
Fortimo LED LLM system based on the lumistep protocol. This is a stand alone
Energy Saving
feature, which will dim the light level for a pre-determinend period (6, 8 or 10 hrs)
per night.
Lightlevel

• Intelligent
 times, works autonomous, reference-points are the switch-on and
switch-off time.
• The functionality integrated in LED driver has to be programmed by factory.
12:00 16:00 20:00 0:00 4:00 8:00 • 3 time lines (6, 8, 10 hours).
• Intelligent timer, works autonomous, reference-points
are the switch-on and switch off time.
• Functionality integrated in LED driver, only has to be The intelligent software which makes up the Lumistep protocol counts the time
programmed by factory. between the switch on and off point for three days in a row and determines the
• 3 timelines (6, 8, 10 hours).
middle point on this data. As most lighting installations make use of the sun rise
Lumistep dimming
and sun set times the mid point of the program is around the same point during
Lumistep 8 hrs dimming a year. From this point the software calculates at which point the dimming should
for the Netherlands in January and July
100% start and stop. So in the summer the standaard dimming period can be as long as
the period between switching on and off (the night period). This is illustrated in
Energy Saving
picture: Example differences dim period January and July.
Lightlevel

January
July

12:00 16:00 20:00 0:00 4:00 8:00

Example differences dim period January and July

The dimming characteristics of the Fortimo LED LLM makes use of a so called
700 mA amplitude (AM) dimming protocol. Most LED systems use PWM (pulse width
modulation), which means that the current is switched on/off at high frequency.
LED Current

50% lightlevel

When dimming the time between the on and off switching increases. AM dimming
700 mA AM Dimming
reduces the current through the LEDs to achieve lower light levels and another
advantage is that there is no:
LED Current

100% lightlevel
700 mA • No audible noise during dimming.
LED Current

50% lightlevel • No visual interference with other lighting or video sources.

PWM Dimming 3.11 Electromagnetic compatibility


Electromagnetic compatibility, EMC, is the ability of a device or system to operate
System efficiency(module+driver) satisfactorily in its electromagnetic environment without causing unacceptable
60.00 Measured with passive cooling, 2000Lm, 4000K
interference in practical situations. When connecting the Functional Earth (FE) of
55.00
50.00 the driver the system will always be compliant to the electromagnetic compatibility
Eff ic. [Lm/W]

45.00 requirements as laid down in European Norms EN 55022, EN 61000-3-2 and


40.00 More then 30% efficiency
increase during dimming EN 61547. However, in some applications it can be that the system will also be
35.00
30.00 compliant to the EMC norms even without connecting the Functional Earth. When
At low dimming levels the driver losses
25.00
become relatively dominant, but the efficiency there is no possibility to connect the FE the EMC behavior of the system might be
20.00 benefit is still very large
0 100 200 300 400 500 600 700 800 improved by connecting the driver FE to the aluminum base of the light module.
I_LED[mA]
Fortimo AM Dimming Fortimo PWM Dimming
with heatsink with heatsink

Design-in guide Philips Fortimo LED Linear system 13


3.12 Exposure to direct sunlight
Exposure to direct sunlight during operation may have severe temperature
or UV effects. Where this situation is likely, extensive temperature testing is
recommended. The Fortimo LED LLM systems are build-in systems, so this is
expected to be negligible.

3.13 Vibration and shocks


Shock resistance: 50 g @ 6 ms semi-sinusoidal.
Vibration resistance: sweep 50-150 Hz, one hour at resonance frequency (all
3 axes) without failure.

3.14 Standards and approvals


Philips Fortimo LED LLM systems comply with the following international rules
and regulations, including:
Safety EN/IEC 60598-1 & 2-2, EN 61347-1, 2-13
Approvals ENEC 05
Philips Fortimo LED LLM systems carry the CE marking. CE is the abbreviation
of Conformité Européenne. It expresses conformity of products to mandatory
requirements of the European Community Directives. The CE mark acts as a
‘passport’ that allows goods to circulate freely throughout the European Union.
Furthermore, it simplifies inspection by Market Controlling Bodies. Two European
directives cover lighting products: the Electromagnetic Compatibility (EMC)
Directive and the Low Voltage Directive (LVD). The Philips Fortimo LED LLM
system carries the CE marking on the basis of compliance with the following
standards: EN 61547, EN 61000-3-2, EN 55015 and EN 55022

3.15 IP codes, dust and moisture protection


The Fortimo LED LLM modules and LLM drivers are build-in systems and have
therefore no IP classification. The Fortimo LED system is not designed for
operation in free air. The OEM is responsible for proper IP classification and
approbation of the luminaire.

3.16 Glow-wire test


Philips Fortimo LED LLM systems conform to the 960 degree glow-wire test.
Reference test: according to additional national deviations for clause 13.3 (Annex
2c of EN 60598-1). An exception is made for France, where local regulations are
more strict.

3.17 End-of-life behavior


Unlike typical conventional light sources, LEDs are not subject to sudden failure or
burnout. There is no time at which the light source will cease to function. Instead,
the performance of LEDs shows gradual degradation over time.
When used according to specification, Fortimo LED LLM modules are predicted
to deliver an average of 100% of their initial intensity after 50,000 hours operation.
This is archieved via the CLO (Constant Light Output ) feature. To compensate for
the gradual degradation of the LEDs a predictive algorithm is used.

14 Design-in guide Philips Fortimo LED Linear system


The lifetime of the system is therefore more dependent on the other electronic
system components and soldering methods. The LEDs in the Fortimo LED LLM
module are connected in series. If one LED fails, this may be due to an internal
short-circuit (character of blue LEDs). In this case it will still conduct current, so
that the other LEDs will still operate.

3.18 About the Fortimo LED Linear Light module


The LED module consists basically of four main components:
• PCB with LEDs.
• Mixing chamber.
• Heat spreader.
• Diffuser with remote phosphor technology.

High-quality white light with high efficiencies is achieved with a plain PCB with
LEDs and a remote phosphor film layer. The mixing chamber ensures perfectly
mixed light, resulting in uniform colors and good color consistency. The heat
spreader facilitates optimal heat transfer and helps luminaire manufacturers to
design their own heat sink system. The heat spreader is equipped with a hole
on either side of the module for fixing. The function of the diffuser is to shape
the light output, resulting in a batwing distrubution. In this manner the luminaire
manufacturer has the freedom to design its own secondary optics. The overall
Exploded view Fortimo Light module dimensions of the LED module, i.e. the combination of heat spreader and mixing
chamber, is optimized for lumen packages varying from 1100 lumen to 4500 lumen.

3.19 About the Fortimo LLM driver


The highly efficient Fortimo LLM driver is specially designed to operate the
Fortimo LED Linear Light Module. It is designed to operate high-power LEDs.
• Maximum current settings of 700mA.
• Max. 80V enables operation of many LEDs in series.
• High efficiency: .90% at full load (220-240 V).
• Tcase life = 55 °C.
• Safety Class 2 system.
Fortimo LLM Driver

Design-in guide Philips Fortimo LED Linear system 15


3.20 About the Fortimo LLM cable
For connecting a Fortimo LLM driver to a Fortimo LED Linear Light module a
specific cable has been developed. The standard Fortimo LED LLM cable is 250 mm.
We advise to use the Fortimo LED LLM cable, if an OEM prefers to use a cable
with a different length it has to organize this itself.
The cable specification should meet UL & IEC/EN requirements. However, approval
of the Fortimo LED LLM module and LED driver is based on a reference luminaire
with the standard 250 mm cable length. In any case, any luminaire design needs
its own approval, organized by the responsible OEM, irrespective of the length of
cable used. If an OEM prefers to have a cable with a different length it can use the
following cable/connector specifications:

JST connector:
Housing JST XAP-05V-1
Contact JST SXA-001T-P0.6
Cable:
5x Wire 24 AWG UL style 1569 (green, blue, red,yellow, black)
Heat shrink tube

Pin 5: Wire 24 AWG UL style 1569 green = Signal ground


Pin 4: Wirre 24 AWG UL style 1569 Blue = LED module setting
Pin 3: Wire 24 AWG UL style 1569 Red = NTC (thermal control)
Pin 2: Wire 24 AWG UL style 1569 Yellow = Power ground
Pin 1: Wire 24 AWG UL style 1569 Black = Current (power utput)

Fortimo LLM Cable details


3.21 Fortimo LED LLM System disposal
At the end of their (economic) lifetime, appropriate disposal of the Fortimo LED
LLM or its components is recommended. The modules are basically normal pieces
of electronic equipment containing components that at present are not considered
to be harmful to the environment, or which can be disposed of with normal care.
It is therefore recommended to dispose of these parts as normal electronic waste,
according to local regulations.

16 Design-in guide Philips Fortimo LED Linear system


4. Designing a luminaire
4.1 Introduction
The Fortimo LED Linear system is designed as a LED breakthrough in energy
efficacy, comfortable and high quality light. To facilitate the integration of Fortimo
LED Linear in existing luminaires and/or developing new luminaires the interface
points of the system are put down, togheter with recommendation.

4.2 IEC recommendations


The general recommendations for luminaire design by IEC and the national safety
regulations (ENEC, CE, ANSI etc.) are also applicable to Fortimo LED LLM systems.
The luminaire manufacturer is advised to conform to the international standards of
luminaire design (IEC 60598-Luminaires).

4.3 Electrostatic device (ESD) measures


The Fortimo LED LLM systems do not require special ESD measures in a
production environment.

4.4 Wiring
The sticker on the power supply shows the connections layout for the connection
to mains. The minimum diameter for the main cables is 0,2 mm and the maximum
diameter is 1.5 mm². The system should not be serviced when mains voltage is
connected; this includes connecting or disconnecting the Fortimo LLM cable!

4.5 Optical design (Secondary optics)


The Fortimo LED LLM module generates a batwing beam shape, which is a
Fortimo LLM driver & connection layout mains
pragmatic starting point for secondary optic design by OEMs. Secondary optics are
not part of the Fortimo LED LLM system offering as this is an added value area for
OEMs. Meanwhile a complementary reflector business around the Fortimo LED
LLM is developing by several companies like Alux Luxar and Jordan. A Ray-set will
become available upon request.

Design-in guide Philips Fortimo LED Linear system 17


4.6 Thermal management
For optimal performance the Fortimo LED LLM system must operate within
specified temperature limits. Depending on the application and luminaire design a
suitable solution for the thermal management should be applied.

4.6.1 Test requirements


Temperature measurements should only be performed when the luminaire is
thermally stable, which may take 0.5 to 2 hours depending on the thermal capacity
of the luminaire (see also the relevant clauses in IEC 60598). For all measurements
such as temperature, luminous flux and power, a stabilization period of at least half
an hour must be allowed before any reliable data can be obtained. Measurements
must be performed by means of thermocouples that are firmly glued to the surface
(and not, for example, secured with adhesive tape).

4.6.2 Temperature range


Because LEDs are temperature-sensitive, LED modules require a different approach
with respect to thermal management. The system has been designed to operate
between -20 °C and 75 °C at Tcase.
The lower and upper limit has been determined by the application and by the
components used in direct relation to the performance and reliability of the
system.

4.6.3 Critical temperature points (Tc)


For LEDs the junction temperature is the critical factor for operation. Since
there is a direct relation between the case temperature and the LED junction
temperature it is sufficient to measure the aluminum casing of the LED module
at its critical point (Tc). The Tc point is located on the back surface of the
LED module and for the driver it is noted on the label of the driver. If the case
temperature at the Tc point exceeds the recommended Tc life of 55 °C the
performance of the LEDs and the fortimo LED system will be adversely affected, in
Tc point light module terms of light output, lifetime and lumen maintenance.

120 If due to insufficient thermal management or other circumstances the Tc point


100
reaches 75 °C, a thermal circuit* will be engaged. This circuit will start dimming the
LED module. The thermal circuit is only a fail save in order to protect the module
Relative light output

80
against overheating.
60
The optimum performance is only archived if Tc point stays below 55 °C. The
40
graph shows the effect on the relative flux as a function of Tc temperature.
20

0 Note:
25 35 45 55 65 75 85
Temperature The thermal circuit is applied in all Fortimo LED Linear versions.
Relative light output

18 Design-in guide Philips Fortimo LED Linear system


4.6.4 Operation under built-in conditions
The heat produced by the LED driver and LED module in the luminaire (or similar
housing) must be dissipated to the surroundings, if this is not taken care of it will
have an adverse effect on system performance and lifetime.

4.6.5 Heat sink design


To ensure performance it is essential that the critical temperature of module
Luminaire
and driver stays below 55 °C. The thermal management can be done in 3 ways
Radiation
conduction, radiation and convection or a combination of these. The figure explains
the 3 terms.

Conduction Heat sink


Convection
Thermal interface
material

Heat spreader

LEDs
Note:
The objective of this chapter is not to indicate exactly how to calculate a heat sink, but to
give some guidelines on how to improve its performance.
3 types of heat transport
4.6.6 Heatsink material
The type of material used has a relatively large influence on the final result. For
example, a comparison of the thermal conductivity (k) of copper with that of
corrosion-resistant steel (see table left) shows that a substantially smaller heat
sink can be made with copper. In practice the best material for heat sinks is (soft)
aluminum. The thickness (H) of the heat sink is also of major importance. Assuming
that we would use the same heat sinks but made from different material a similar
effect would be archived with 1 mm copper, 2 mm aluminum, 4 mm brass, 8 mm
steel or 26 mm corrosion-resistant steel.

Material W/mK 4.6.7 Thermal radiation and emission coefficient


Copper 400 Thermal radiation can also form a substantial part of the total heat transfer, and
Aluminum 200 is of the same order as for convection. This depends strongly on the emission
Brass 100 coefficient (see table) of the surface, which lies between 0 and 1. For example,
Steel 50 a polished aluminum surface has a very low emission coefficient, while that of a
Corrosion-resistant steel 15 painted surface is very high.
Thermal conductivity

Material W/mK Emission coefficient


Aluminium new/polished 0.04 - 0.06
oxidized 0.2 - 0.3
anodized 0.8
Steel painted 0.8 - 0.95
new/polished 0.03 - 0.07
heavily oxidized 0.7 - 0.8
Emission coefficients

Design-in guide Philips Fortimo LED Linear system 19


Cost of heatsink 4.6.8 Surface area
Although a heat sink can have many (complex) shapes the design will depend
Heatsink surface [dm2]

14
Heatsink on several parameters. Depending on application of the luminaire the required
surface area, cost, thermal resistance and volume inside of the luminaire can be
Heatsink (plate shape)
7 determined. Here is a differentiation opportunity for luminaire manufacturers.
3
The first generation Fortimo LED LLM products have an initial energy
4 7 20
Volume Luminaire [dm3] consumption of 28 W for the 1800 lm version and 17 Watt for the 1100 lm
warm white version. The amount of heat (energy) that needs to be taken form the
Typical volume Cobrahead luminaire Typical volume Pole Top luminaire
module is about 14 W for the 1800 lm and 9 W for the 1100 version. The heat
Indication of luminaire volume vs heatsink surface and cost spreader at the back side of the module is the contact area for the external heat
(Fortimo LED Linear 1800 lm) sink. The external heatsink transports the heat away from the module.

By improving the thermal management, in other words lowering the Tc point of


the LED module, the system will perform better (lifetime and light output). Here
is another differentiation opportunity for luminaire manufacturers. The size of the
heat sink depends on the power rating of the module the design and volume of the
luminaire.

A typical surface area of a heat sink, when passively cooled, for a 1800 lm system is
10,40 dm2 whilst the 1100 Lm module requires a heat sink with a surface area of
6,30 dm2 this is based on a “standard” heat sink of aluminium with outer dimensions
of 250x40x50 mm (LxHxB) and a inside volume of the luminaire of 7 dm3.

Once LED efficiency upgrades become available, power rating will be reduced and
required heat sink size can also be reduced.

4.6.9 Thermal design


If one wants to calculate the required surface area of the heatsink a relatively
Luminaire
simple model can be used as shown in the thermal model graph.

Tambient luminaire

Rthermal-luminaire
Tambient
Rthermal-heatsink

Tc

Thermal model

20 Design-in guide Philips Fortimo LED Linear system


4.6.10 Calculation of thermal resistance
The total thermal resistance (Rth_tot) of the system is equal to the thermal
resistance of the heat sink (Rth_hs) plus the thermal resistance of the luminaire
(Rth_lum). For the reference calculation we have used the following temperatures
Tc = 55 °C and T ambient is 35 °C and T ambient luminaire is 15 °C.

Rth_total = Rth_heatsink + Rth_luminiare

The Rth_hs is calculated by subtracting Tambient from Tc and devided by the


Pdissipation of the Light module.
Tc_Tambient
Rth_heatsink = Pdissipated light module

35º C - 15º C
Rth_heatsink = 14 W = 1.43º C/W

The Rth_lum is calculated

Tambient - Tambient luminaire


Rth_luminaire = Pdissipated light module & driver

35º C - 15º C
Rth_luminiare = 14 W + 3 W = 1.18º C/W

The Rth_total is then

Rth_total = 1.43 + 1.18 = 2.61º C/W

4.6.11 Thermal management


Tambient luminaire To simplify thermal management the OEM can design the heatsink in such a way
that it becomes one with the luminaire housing. By making the housing of the
luminaire an integral part of the heat management which greatly reduces the
Rthermal-luminaire surface area of the “internal heatsink” and simplifies the calculation.

4.6.12 Calculating your heat sink


Tc
So a first indication of the surface area can than be calculated with:
1
Total surface area heat sink = Rth_heat sink x h

1
Luminaire Total outer surface area heat sink = 1,43 x 7 = 0.099 m2
Termal model with integrated heatsink
The h in the equation is the heat transfer coefficient (W/m2). Typical the h value is
between 5-10.

If you need expert advise we recommend that you contact of the complentary
partners for heat management.

Design-in guide Philips Fortimo LED Linear system 21


4.7 Recommendations
4.7.1 Optical
To proof the Fortimo Led Linear concept a reference design has been made.
Based on a typical residential street of 8 meters and a poleheight of 6 meters
a poledistance of 30 meters can be archived with making the international S5
residential ligting norm.
If you require support in optical design we suggest that you contact one of the
complementary partners.You will find information on these partners in the
appendix.

4.7.2 Thermal interface


To increase the conduction of heat it is always advisable to use Thermal interface
material (TIM). There are several good solutions available in the market place.
We have good experience with the 3 below.
• Bergquist Gappad 1500S30/1500R
• Chomerics G569/579
• Laird T-flex 220
If you require further support for thermal interface material we suggest that you
contact one of the complementary partners (see chapter 5 appendix).

22 Design-in guide Philips Fortimo LED Linear system


5. Appendix
5.1 Example Fortimo LED LLM solution
To proof the Fortimo LED Linear we have made a prototype luminaire solution, for
reference purposes. The luminaire is made from plastic and has an inner volume of
7 dm2. We will use this luminaire to litt up a street in a residential area. The street
is 8 meter wide and the poles standing 30 meter apart. The height of the pole is
6 meters. The average temperature is 15 °C. Furthermore this pole is situated in
a residential area and we should comply with the S5 norms as stated in the
European BS EN 13201-2.

It is possible of course to comply with higher norms by moving the poles closer
together or reducing the pole height to 4 meters but that is up to the OEM.
Example of luminaire with Fortimo LED LLM system
5.2 Complementary partners for optics
Jordan : www. ordanreflectors.co.uk
Alux Luxar : www.alux.de

5.3 Complementary partners for heatsinks


Sapa : www.spagroup.com/thermalmanagement
Nuventix : www. nuventix.com
HS Marston : www. hsmarston.co.uk
AVC : www.avc.com.tw

5.4 Complementary partners for thermal interface material


Laird : www.lairdtech.com
Bergquist : www.bergquistcompany.com
Chomerics : www.chomerics.com

Design-in guide Philips Fortimo LED Linear system 23


Index of visuals
3 types of heat transport 19
Batwing light distribution 10
City Application 4
Color consistency (SDCM) 7
Cutoff section LED 6
Emission coefficients 19
Example differences dim period January and July 13
Example of luminaire with Fortimo LED LLM system 23
Exploded view Fortimo Light module 15
Fortimo LED Linear System 8
Fortimo LLM Cable details 16
Fortimo LLM Driver 15
Fortimo LLM driver 3
Fortimo LLM driver 9
Fortimo LLM driver & connection layout mains 17
Fortimo LLM module 3
Fortimo LLM module 9
Indication of luminaire volume vs heatsink surface and cost
(Fortimo LED Linear 1800 lm) 20
Lumistep dimming 13
LUXEON Rebel LED 6
Outdoor Park application 4
Overlighting versus CLO 12
Polar diagrams Fortimo LED Linear 10
Relative light output 18
Residential area application 4
Tc point light module 18
Termal model with integrated heatsink 21
Thermal conductivity 19
Thermal model 20
Wavelength (nm) 11
Wavelength (nm) 11

24 Design-in guide Philips Fortimo LED Linear system


Design-in guide Philips Fortimo LED Linear system 25
26 Design-in guide Philips Fortimo LED Linear system
Design-in guide Philips Fortimo LED Linear system 27
For more information please visit:
www.philips.com/fortimo
www.asimpleswitch.com
www.philips.com/oem

© 2009 Koninklijke Philips Electronics N.V.


All rights reserved. Reproduction in whole or in part is prohibited without the prior written consent of the copyright owner. The information presented in
this document does not form part of any quotation or contract,is believed to be accurate and reliable and may be changed without notice. No liability will
be accepted by the publisher for any consequence of its use. Publication thereof does not convey nor imply any license under patent or other industrial or
intellectual property rights.

Document order number: 3222 635 72661


11/2009